Blower Motor Surgery 5000/200 Models

[scott.john.mockry@bangate1.tek.com]

This past weekend I used Mitch Loescher's recommended procedure for replacing the blower
motor in  my 89 200TQ. A couple of years ago on my 86 5000, I used the factory procedure
for replacing the blower motor that involved removing the blower motor housing etc. I was
open to any short cuts on this procedure.

Well, the car survived the surgery, and I am happy to report that I am the proud father of a 
new air sucking device (blower) that works great. I do have a few tips for anyone who 
chooses to use  this method.

Step #1. Use a razor blade to cut your finger and drip some blood on the blower housing.
(This is will appease the Audi Gods and avoid further blood letting later in the process.)

Step #2. As mentioned before, Cut away and remove the black plastic tube that connects 
the blower housing and the A/C evaporator housing.

Step #3. Remove the 3 screws that hold on the white plastic inlet piece on the blower motor
housing. The bottom screw appears to be unreachable, but a 11 1/2 inch long phillips screw
 driver will reach the screw if a mirror is used to view and locate the screw. 
Remove this inlet piece up and out from the blower housing.  Remove the retaining circlip 
and electrical connector from the other end of the blower motor.

Step #4. Cut away about 1 inch of the upper portion of the round outlet of the A/C evaporator
housing. A  hacksaw blade works great for this. You can also trim some of the upper inlet of
the blower housing as well using a utility razor knife. This modification allows the blower 
squirrel  cage to be  swung upward and out with minimum distortion (squeezing) of the round 
plastic  squirrel cage. NOTE: You should wear some thin cotton gloves when you grab the plastic
squirrel cage to remove the motor. The sqirrel cage blades are sharp as my finger 
tips can attest to, and even though bleeding on the blower housing does heighten the 
experience and makes the Audi Gods smile, it can get messy.

CAUTION: When I tried to  remove the old blower motor before I cut this section of
the A/C housing out,  I ended up cracking the plastic squirrel  cage on the old blower motor. 
I was a bit paranoid about  breaking the New blower squirrel cage so cutting out this section
 on the A/C housing allowed a minimum of distortion on the plastic squirrel cage during 
installation. The new plastic squirrel cage was more flexible than the old one and went in
 without a hitch. 

Step #5 After re-installing the white inlet piece on the blower housing, a flexible
piece of 6 inch duct  and clamps can be used to reconnect the blower housing and the A/C
housing. You could also use some 6 inch sheet metal duct work as well. The use of Duct tape
should not be overlooked to seal up some of the gaps. Oh, and keep some bandaids handy
as well.

That's all folks, the process took a couple of hours but this time could be shortened knowing
what I know now.
Scott M.